Sole structure with customizable bladder network

Abstract

A method for manufacturing a sole structure. Data is received for a cushioning profile of the sole structure of an article of footwear, the sole structure including a bladder network including multiple bladders interconnected by conduits, the sole structure also including a plurality of openings exposing the conduits. Based on the received data, configurations of at least some stems in a frame are adjusted. The frame is installed into the sole structure, the installing including inserting the stems through the openings so as to at least partially close at least a portion of the conduits.

The invention claimed is: 
     
       1. A method for manufacturing a customized sole structure, comprising:
 receiving data for a cushioning profile of the sole structure of an article of footwear, the sole structure including a bladder network including multiple bladders interconnected by a plurality of conduits, wherein each conduit, of the plurality of conduits, interconnects a different pair of the bladders, of the multiple bladders; 
 forming a plurality of openings in a bottom of a midsole and extending through the bottom of the midsole and further comprising at least partially incorporating the bladder network into the midsole, wherein each of the plurality of openings corresponds to, and is positioned below, a respective conduit, of the conduits, interconnecting a pair of the bladders; 
 based on the received data, adjusting configurations of at least some stems in a frame; and 
 installing the frame into the sole structure, the installing including inserting the stems downward through the openings so as to at least partially close at least a portion of the conduits, wherein each of the stems corresponds to, and is positioned in, a respective opening of the plurality of openings to control if, or how fast, fluid flows between pairs of bladders and respective conduits to control firmness when the sole structure is compressed by a wearer. 
 
     
     
       2. The method of  claim 1 , wherein adjusting configurations of at least some stems comprises 3D printing the at least some of the stems to desired lengths. 
     
     
       3. The method of  claim 1 , wherein adjusting configurations of at least some stems comprises, as to each of those stems, removing a portion of that stem. 
     
     
       4. The method of  claim 1 , further comprising covering at least a portion of the bottom of the midsole with an outsole, and wherein the openings extend through the outsole. 
     
     
       5. The method of  claim 1 , further comprising locating first and second bladders in a forefoot region and third and fourth bladders in a heel region, wherein the conduits comprise a first conduit interconnecting the first and second bladders and a second conduit interconnecting the third and fourth bladders, and positioning first and second openings respectively below the first and second conduits, and positioning first and second stems respectively in the first and second openings and at least partially closing the first and second conduits to at least partially restrict fluid flow between respective bladders. 
     
     
       6. The method of  claim 1 , further comprising displacing first and second bladders from each other in a medial-lateral direction and displacing third and fourth bladders from each other in a heel-toe direction, interconnecting a first conduit with the first and second bladders and a second conduit with the third and fourth bladders, and positioning first and second openings respectively below the first and second conduits, and positioning first and second stems respectively in the first and second openings and at least partially closing the first and second conduits to at least partially restrict fluid flow between respective bladders. 
     
     
       7. The method of  claim 1 , wherein the frame is removable from the sole structure without damaging the frame or the sole structure. 
     
     
       8. The method of  claim 1 , wherein each of the stems comprises a retaining ridge extending outward, wherein each of the openings comprises a wall having a recess conforming to the retaining ridge of the corresponding stem. 
     
     
       9. The method of  claim 1 , comprising forming the bladder network from first and second sheets of material that are not permeable by a fluid, and bonding the first and second sheets of material to form seams and define the multiple bladders and the conduits.